Multi-purpose tile system

ABSTRACT

A multi-purpose tile system including first coupling parts and at least one second coupling parts, at least a part of a side of an upward tongue facing away from an upward flank of the first coupling part includes a first locking element which is adapted for co-action with a second locking element of the at least one second coupling part of an adjacent tile, a downward flank of the second coupling part is provided with a second locking element adapted for co-action with a first locking element of the first coupling part of an adjacent tile, said first and second locking elements being formed by a vertical flat portion and a bulge-recess combination, wherein the first locking element is positioned at a distance from an upper side of the upward tongue, wherein the second locking element is positioned at a distance from an upper side of the downward groove.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/610,578, filed Nov. 4, 2019, which is the United States nationalphase of International Application No. PCT/EP2018/063520 filed May 23,2018, and claims priority to Dutch Patent Application No. 2018970 filedMay 23, 2017, the disclosures of which are hereby incorporated byreference in their entirety.

BACKGROUND OF THE INVENTION Field of the Invention

The invention relates to a multi-purpose tile system, in particular afloor tile system, comprising a plurality of multi-purpose tiles. Theinvention also relates to a tile covering, in particular floor covering,consisting of mutually coupled tiles according to the invention. Theinvention further relates to a tile for use in multi-purpose tile systemaccording to the invention.

Description of Related Art

Interconnectable tiles or panels, such as interconnectable floor panels,are generally joined mechanically at edges of the panels by usingcomplementary coupling profiles at opposite edges. Traditionally,rectangular floor panels are connected at the long edges by means of atraditional angling method. On the short side, the different couplingmechanisms can be applied, wherein a short edge coupling mechanism may,for example, be based upon vertical folding, also referred to as a dropdown, wherein a downward tongue located at a short edge of a panel to becoupled is moved in downward direction, such that said downward tongueis inserted into an upward groove located at a short edge of a panelalready installed. An example of such a panel is disclosed in U.S. Pat.No. 7,896,571, wherein a short edge coupling mechanism is shown beingconfigured to vertically lock mutually coupled short edges of adjacentpanels. Although this aimed vertical locking effect at the short edgesis intended to stabilize the coupling between floor panels at the shortedges, in practice often breakages, due to coupling edges being putunder tension both during assembly and during practical use, occur atthe coupling edges, which affects the reliability and durability of thistype of drop down coupling.

Further examples of interconnectable tiles are disclosed in DE202016102034 which discloses coupling parts having a horizontally activelocking system. WO 2016/113706 discloses floor panels that can beinstalled according to the fold down-technique, which comprises couplingmeans in one piece on all four edges. EP 2647781 discloses a floorboardwhich is capable of absorbing, expansion and contraction, wherein theboard makes use of tongue-groove coupling structures. EP 3141674discloses a floor member with a closed-cell foam core which has edgeconnecting means for convenient floating floor installation without theneed to adhere the floor member to a floor base. WO 201 5/1 301 69discloses a floor panel which is interconnectable with similar panelsfor forming a floor covering. EP 3020885 discloses panels havinginterconnecting coupling means which panels are suitable for assemblinga waterproof floor covering.

A first objective of the invention is to provide an improved panel whichcan be coupled in improved manner to an adjacent panel.

A second objective of the invention is to provide an improved panelcomprising an improved, in particular relatively reliable, drop downcoupling mechanism.

A third objective of the invention is to provide an improved panelcomprising an improved drop down coupling mechanism, wherein the risk ofdamaging, in particular breakage of, the drop down coupling mechanism isreduced.

A fourth objective of the invention is to provide an improved panelcomprising an improved drop down coupling mechanism, wherein the risk ofdamaging, in particular breakage of, the drop down coupling mechanismduring both coupling and uncoupling is reduced.

SUMMARY OF THE INVENTION

In order to achieve at least one of the above objects, the inventionprovides a tile wherein a rigid closed cell foam plastic material usedin a base layer provides the tile as such a desired rigidity androbustness preventing damaging, and in particular breakage, of thecoupling parts (during normal use). An additional advantage of using afoam plastic material is that the presence of closed cells not onlyleads to improved rigidity and improved impact resistance, but also toreduced density and lighter weight in comparison with dimensionallysimilar non-foam plastic material. The rigidity of the base layer isfurther improved by applying a toughening agent, wherein the base layerof closed cell foam plastic material contains 3% to 9% by weight of thetoughening agent. Because the coupling parts are given a specific form,the substantially complementarily formed coupling parts of adjacenttiles can be coupled to each other relatively simply, but durably andefficiently. During coupling of adjacent tiles, a force will here beexerted on one or both coupling parts, whereby the one or both couplingparts will slightly and temporarily (resiliently) deform to some extent,as a consequence of which the volume taken up by the downward grooveand/or upward groove will be increased, such that the upward tongue andthe downward tongue can be arranged relatively simply in, respectively,the downward groove and the upward groove. By subsequently allowing theforced coupling parts to move back (resiliently) to the originalposition, a reliable, locked coupling will be realized between the twocoupling parts, and thereby between the two tiles. Hence, the firstcoupling part may be considered as resilient first coupling part. Thesecond coupling part may be considered as resilient second couplingpart. Due to the rigidity of the base layer, and due to the fact thatthe at least a part of the coupling parts will typically be integratedwith said base layer (at least in some embodiments), the resiliency ofthe coupling parts will commonly be very restricted though sufficient toallow tiles to be coupled and uncoupled. This locked coupling, whereinboth coupling parts mutually engage in a relatively reliable manner, andwhich commonly results in a locking effect between two tiles both in ahorizontal direction and in a vertical direction, will preferably bewithout play, which counteracts the risk of the occurrence of creakingnoises. Hereby, it is aspired to reduce this risk by a suitable designof the profiles of the coupling parts, such that the risk of saidundesired noises is reduced even if no sliding agent is applied, which,however, does not exclude that a sliding agent still can be applied onthe coupling parts of the tiles according to the invention. The designof the coupling parts of the tiles, together with the rigidity of thepanel, allows tiles to be coupled to an already installed tile by meansof a mutual linear displacement in vertical direction (i.e., a directionperpendicular to a plane defined by said already installed tile) and/orby means of a zipping action (scissoring action). Hence, the design ofthe coupling parts of the tiles, together with the rigidity of thepanel, leads to a system of multi-purpose tiles which can be installedin a user-friendly and durable and reliable manner. Moreover, the designof the coupling parts of the tiles, together with the rigidity of thepanel, allows coupled multi-purpose tiles to be uncoupled withoutbreaking the tiles, after which the tiles can be reused. The appliedaligning edges, generally also referred to as chamferings or guidesurfaces, herein facilitate hooking together of the two coupling partsby the substantially linear displacement of the coupling parts relativeto each other. Because both the (optional) first locking element and the(optional) second locking element are integrally part of therespectively upward tongue and the downward flank, the vertical (androtational (angular)) locking effect between coupled panels can beimproved. At least a part of the coupling parts typically make theintegral part of the base layer, and are therefore made of the samematerial as the base layer (closed cell foam plastic material). Thecharacteristic orientation of the side of the upward tongue facingtoward the upward flank, and the side of the downward tongue facingtoward the downward flank, provides for a locking effect between coupledtiles both in horizontal direction (parallel to the plane defined by thetiles) and in vertical direction (perpendicular to the plane defined bythe tiles). This is because owing to the characteristic incliningorientation of the tongue walls facing toward the respective flanks, theexerting of (for instance) a vertical force on the coupling will merelylead to uncoupling of co-acting coupling parts after a serious verticalforce (perpendicular to the plane defined by the tiles) is exerted onthe second coupling part, in a direction away from the first couplingpart, which can be established, for example, by using a specificuncoupling tool typically provided with a suction cup. The seriousforces exerted to the tile(s) can be absorbed by the tile due to theapplication of the rigid core layer at least partially made of closedcell plastic foam. In addition to the aforementioned inner lockingmechanism, an outer locking mechanism is preferably formed by thelocking elements which co-act mutually, and furthermore at a distancefrom the above mentioned (inner) tongue walls, in a coupled position oftwo tiles. The combination of said inner locking mechanism and saidouter locking mechanism, positioned at a distance from said innerlocking mechanism, also leads to a locking effect in a rotationaldirection which counteracts the tiles in coupled condition to mutuallypivot. Moreover, in case of possible failure of one of the lockingmechanisms, securing of the coupling between the two tiles will bemaintained as far as possible, resulting in a relatively reliablecoupling between the two tiles, whereby undesirable mutual displacementor uncoupling of the tiles can still be prevented as far as possible.

The tile according to the invention is a light-weight multi-purpose tilethat can be used, for example, as a ceiling tile, a wall tile a floortile, or as component of a piece of furniture. The tile can be directlybonded to a ceiling, wall or floor surface. The tile can also be used asa ceiling tile in a suspended or hung ceiling assembly having gridsections that support the tile. When used as a wall covering, the tilecan be folded to continuously fit within an inside corner ofintersecting walls or wrap around an outside corner. When used as afloor covering, the tile can be installed with other similar tiles in afloating floor assembly, wherein the tiles are not bonded directly to afloor base. The multi-purpose tile is relatively inexpensive tomanufacture and does not require special skills or training to handleand install, making it attractive for do-it-yourself individuals whohave had no previous experience installing tiles. Due to the waterproofproperties of the base layer, and preferably of the tiles as such, thetiles may be used both indoor and outdoor. The tiles according to theinvention may also be referred to as panels. The base layer may also bereferred to as core layer. The coupling parts may also be referred to ascoupling profiles.

Foam plastic materials suitable for forming the foam base layer mayinclude polyurethane, polyamide copolymers, polystyrene, polyvinylchloride (PVC), polypropylene and polyethylene foamed plastics, all ofwhich have good moulding processability. Polyvinyl chloride (PVC) foammaterials are especially suitable for forming the foam base layerbecause they are chemically stable, corrosion resistant, and haveexcellent flame-retardant properties. Preferably, chlorinated PVC (CPVC)and/or chlorinated polyethylene (CPE) and/or another chlorinatedthermoplastic material is/are used to further improve the hardness andrigidity of the base layers, and of the tiles as such. The plasticmaterial used in as foam plastic material in the base layer is free ofany plasticizer in order to increase the desired rigidity of the baselayer, which is, moreover, also favourable from an environmental pointof view. Foam plastic materials according to the invention also includefoamed plastic composites and foamed composites including plasticmaterials. The substantially rigid base layer of each tile is at leastpartially composed of a composite comprising a closed cell foam plasticmaterial and at least one filler. Conventional materials, like HDF andMDF, are weaker than the aforementioned foamed composite, and willeasily lead to breakage and/or damaging. The composite of the base layercomprises one or more fillers, wherein at least one filler is selectedfrom the group consisting of: talc, chalk, wood, calcium carbonate,titanium dioxide, calcined clay, porcelain, a(nother) mineral filler,and a(nother) natural filler. The filler may be formed by fibres and/ormay be formed by dust-like particles. Here, the expression “dust” isunderstood as small dust-like particles (powder), like wood dust, corkdust, or non-wood dust, like mineral dust, stone powder, in particularcement. The average particle size of the dust is preferably between 14and 20 micron, more preferably between 16 and 18 micron. The weightcontent of this kind of filler in the composite is between 40 and 48% incase the composite is a foamed composite, and preferably between 65 and70% in case the composite is a non-foamed (solid) composite. The fillerof the base layer may for instance be selected from the group consistingof: a salt, a stearate salt, calcium stearate, and zinc stearate.Stearates have the function of a stabilizer, and lead to a morebeneficial processing temperature, and counteract decomposition ofcomponents of the composite during processing and after processing,which therefore provide long-term stability. Instead of or in additionto a stearate, for example calcium zinc may also be used as stabilizer.The weight content of the stabilizer(s) in the composite will preferablybe between 1 and 5%, and more preferably between 1.5 and 4%.

The base layer, or the composite of the base layer preferably comprisesat least one impact modifier comprising at least one alkylmethacrylates, wherein said alkyl methacrylate is preferably chosen fromthe group consisting of: methyl methacrylate, ethyl methacrylate, propylmethacrylate, isopropyl methacrylate, t-butyl methacrylate and isobutylmethacrylate. The impact modifier typically improves the productperformance, in particular the impact resistance. Moreover, the impactmodifier typically toughens the base layer and can therefore also beseen as toughening agent, which further reduces the risk of breakage.Often, the modifier also facilitates the production process, forexample, in order to control the formation of the foam with a relativelyconsistent (constant) foam structure. The weight content of the impactmodifier in the composite will preferably be between 1 and 9%, and morepreferably between 3 and 6%.

The base layer may also at least partially be composed of a (PVC-free)thermoplastic composition. This thermoplastic composition may comprise apolymer matrix comprising (a) at least one ionomer and/or at least oneacid copolymer; and (b) at least one styrenic thermoplastic polymer,and, optionally, at least one filler. An ionomer is understood as beinga copolymer that comprises repeat units of electrically neutral andionized units. Ionized units of ionomers may be in particular carboxylicacid groups that are partially neutralized with metal cations. Ionicgroups, usually present in low amounts (typically less than 15 mol % ofconstitutional units), cause micro-phase separation of ionic domainsfrom the continuous polymer phase and act as physical crosslinks. Theresult is an ionically strengthened thermoplastic with enhanced physicalproperties compared to conventional plastics.

The density of the foam base layer typically varies from about 0.1 to1.5 grams/cm³, preferably from about 0.2 to 1.4 grams/cm³, morepreferably from about 0.3 to 1.3 grams/cm³, even more preferably fromabout 0.4 to 1.2 grams/cm³, even more preferably from about 0.5 to 1.2grams/cm³, and most preferably from about 0.6 to 1.2 grams/cm³.

Preferably, the base layer comprises at least one foaming agent. The atleast one foaming agent takes care of foaming of the base layer, whichwill reduce the density of the base layer. This will lead to lightweight tiles, which are lighter weight in comparison with tile which aredimensionally similar and which have a non-foamed base layer. Thepreferred foaming agent depends on the (thermo)plastic material used inthe base layer, as well as on the desired foam ratio, foam structure,and preferably also the desired (or required) foam temperature torealise the desired foam ratio and/or foam structure. To this end, itmay be advantageous to apply a plurality of foaming agents configured tofoam the base layer at different temperatures, respectively. This willallow the foamed base layer to be realized in a more gradual, and morecontroller manner. Examples of two different foaming agents which may bepresent (simultaneously) in the base layer are azidicarbonamide andsodium bicarbonate. In this respect, it is often also advantageous toapply at least one modifying agent, such as methyl methacrylate (MMA),in order to keep the foam structure relatively consistent throughout thebase layer.

Each tile preferably comprises an upper substrate affixed to an upperside the base layer, wherein said substrate preferably comprises adecorative layer. The upper substrate is preferably at least partiallymade of at least one material selected from the group consisting of:metals, alloys, macromolecular materials such as vinyl monomercopolymers and/or homopolymers; condensation polymers such aspolyesters, polyamides, polyimides, epoxy resins, phenol-formaldehyderesins, urea formaldehyde resins; natural macromolecular materials ormodified derivatives thereof such as plant fibres, animal fibres,mineral fibres, ceramic fibres and carbon fibres. Here, the vinylmonomer copolymers and/or homo-polymers are preferably selected from thegroup consisting of polyethylene, polyvinyl chloride (PVC), polystyrene,polymethacrylates, polyacrylates, polyacrylamides, ABS,(acrylonitrile-butadiene-styrene) copolymers, polypropylene,ethylene-propylene copolymers, polyvinylidene chloride,polytetrafluoroethylene, polyvinylidene fluoride, hexafluoropropene, andstyrene-maleic anhydride copolymers, and derivates thereof. The uppersubstrate most preferably comprises polyethylene or polyvinyl chloride(PVC). The polyethylene can be low density polyethylene, medium densitypolyethylene, high density polyethylene or ultra-high densitypolyethylene. The upper substrate layer can also include fillermaterials and other additives that improve the physical propertiesand/or chemical properties and/or the processability of the product.These additives include known toughening agents, plasticizing agents,reinforcing agents, anti- mildew (antiseptic) agents, flame-retardantagents, and the like. The upper substrate typically comprises adecorative layer and an abrasion resistant wear layer covering saiddecorative layer, wherein a top surface of said wear layer is the topsurface of said tile, and wherein the wear layer is a transparentmaterial, such that decorative layer is visible through the transparentwear layer.

The thickness of the upper substrate typically varies from about 0.1 to2 mm, preferably from about 0.15 to 1.8 mm, more preferably from about0.2 to 1.5 mm, and most preferably from about 0.3 to 1.5 mm. Thethickness ratio of the foam base layer to the upper substrate commonlyvaries from about 1 to 15: 0.1 to 2, preferably from about 1.5 to 10:0.1 to 1.5, more preferably from about 1.5 to 8: 0.2 to 1.5, and mostpreferably from about 2 to 8: 0.3 to 1,5, respectively.

Each tile may comprise an adhesive layer to affix the upper substrate,directly or indirectly, onto the base layer. The adhesive layer can beany well-known bonding agent or binder capable of bonding together theupper substrate and the foam base layer, for example polyurethanes,epoxy resins, polyacrylates, ethylene-vinyl acetate copolymers,ethylene-acrylic acid copolymers, and the like. Preferably, the adhesivelayer is a hot-melt bonding agent.

The decorative layer or design layer, which may be part of the uppersubstrate as mentioned above, can comprise any suitable known plasticmaterial such as a known formulation of PVC resin, stabilizer,plasticizer and other additives that are well known in the art. Thedesign layer can be formed with or printed with printed patterns, suchas wood grains, metal or stone design and fibrous patterns orthree-dimensional figures. Thus the design layer can provide the tilewith a three dimensional appearance that resembles heavier products suchas granite, stone or metal. The thickness of the design layer typicallyvaries from about 0.01 to 0,1 mm, preferably from about 0.015 to 0.08mm, more preferably from about 0.2 to 0,7 mm, and most preferably fromabout 0,02 to 0,5 mm. The wear layer that typically forms the uppersurface of the tile can comprise any suitable known abrasion-resistantmaterial, such as an abrasion-resistant macromolecular material coatedonto the layer beneath it, or a known ceramic bead coating. If the wearlayer is furnished in layer form, it can be bonded to the layer beneathit. The wear layer can also comprise an organic polymer layer and/orinorganic material layer, such as an ultraviolet coating or acombination of another organic polymer layer and an ultraviolet coating.For example, an ultraviolet paint capable of improving the surfacescratch resistance, glossiness, antimicrobial resistance and otherproperties of the product. Other organic polymers including polyvinylchloride resins or other polymers such as vinyl resins, and a suitableamount of plasticizing agent and other processing additives can beincluded, as needed. The decorative layer or design layer may also bedigitally printed directly onto the core layer.

The plastic foam used in the base layer preferably has an elasticmodulus of more than 700 MPa (at a temperature of 23 degrees Celsius anda relative humidity of 50%). This will commonly sufficiently rigidity tothe base layer, and hence to the tile as such.

Preferably, at a top section and/or a bottom section of the foamed baselayer a crust layer may be formed. This at least one crust layer mayform integral part of the base layer. More preferably, both the topsection and the bottom section of the base layer form a crust layerenclosing the foam structure. The crust layer is a relatively closed(reduced porosity, preferably free of bubbles (cells)), and hence formsa relatively rigid (sub)layer, compared to the more porous foamstructure. Commonly, though not necessary, the crust layer is formed bysealing (searing) the bottom and top surface of the core layer.Preferably the thickness of each crust layer is between 0.01 and 1 mm,preferably between 0.1 and 0.8 mm. Too thick crust will lead to a higheraverage density of the core layer which increases both the costs and therigidity of the core layer. The thickness of the core layer as such ispreferably between 2 and 10 mm, more preferably between 3 and 8 mm.

Preferably, each tile comprises at least one backing layer affixed to abottom side of the base layer, wherein said at least one backing layerat least partially made of a flexible material, preferably an elastomer.The thickness of the back layer is typically at least 0.1 mm and smallerthan 5 mm, and more typically is smaller than 2.5 mm. The backing layercommonly provides additional robustness and impact resistances to eachtile as such, which increases the durability of the tiles. Moreover, the(flexible) backing layer may increase the acoustic (sound-dampening)properties of the tiles. In a particular embodiment, the base layer iscomposed of a plurality of separate base layer segments affixed to saidat least one backing layer, preferably such that said base layersegments are mutually hingeable. The lightweight features of the tilesare advantageous for obtaining a secure bond when installing the tile onvertical wall surfaces. It is also especially easy to install the tileat vertical corners, such as at inside corners of intersecting walls,pieces of furniture, and at outside corners, such as at entry ways. Aninside or outside corner installation is accomplished by forming agroove in the foam base layer of the tile to facilitate bending orfolding of the tile.

At least one reinforcing layer may be situated in between the base layerand the upper substrate. This may lead to further improvement of therigidity of the tiles as such. This may also lead to improvement of theacoustic (sound-dampening) properties of the tiles. The reinforcementlayer may comprise a woven or non-woven fibre material, for example aglass fibre material. They may have a thickness of 0, 2 -0,4 mm. It isalso conceivable that each tile comprises a plurality of the (commonlythinner) base layer stacked on top of each other, wherein at least onereinforcing layer is situated in between two adjacent base layers.

During coupling and uncoupling the coupling parts will commonly beinclined to deform at or in their weakest section. To this end, at leastone coupling part of the first coupling part and second coupling partpreferably comprises a bridge connecting the tongue of said couplingelement to the base layer, wherein the minimum thickness of the bridgeis smaller than the minimum width of the tongue. This will force thebridge(s) rather than the tongue itself to be slightly deformed duringcoupling and uncoupling, which is commonly in favour of the durability(and shape stability) of the tongues, and hence of the durability andreliability of the coupling realized between two panels.

A lower side (lower surface) of an upper bridge of the second couplingpart defining an upper side (upper surface) of the downward groove maybe at least partially inclined, and preferably extends downward towardsthe core of the panel. The upper side (upper surface) of the upwardtongue may, as well, be at least partially inclined, wherein theinclination of this upper side of the upward tongue and the inclinationof the upper bridge of the second coupling part may be identical, thoughwherein it is also imaginable that both inclinations for instancemutually enclose an angle between 0 and 5 degrees. The inclination ofthe bridge part of the second coupling part creates a natural weakenedarea of the bridge part, where deformation is likely to occur.

Each of the upward tongue and the downward tongue is preferablysubstantially rigid, which means that the tongues are not configured tobe subjected to deformation. The tongues as such are relatively stiffand hence non-flexible. Moreover, the tongues are preferablysubstantially solid, which means that the tongues are substantiallymassive and thus completely filled with material and are therefore notprovided with grooves at an upper surface which would weaken theconstruction of the tongue and hence of the tile connection to berealised. By applying a rigid, solid tongue a relatively firm anddurable tongue is obtained by means of which a reliable and the durabletile connection can be realised without using separate, additionalcomponents to realise a durable connection.

In an embodiment of the tile, at least a part of the upward flankadjoining the upper side of the tile is adapted to make contact with atleast a part of the downward tongue adjoining the upper side of anothertile in a coupled state of these tiles. Engagement of these surfaceswill lead to an increase of the effective contact surface between thecoupling parts and hence to an increase of stability and sturdiness ofthe connection between two tiles. In a favourable embodiment the upperside of the tile is adapted to engage substantially seamless to theupper side of another tile, as a result of which a seamless connectionbetween two tiles, and in particular the upper surfaces thereof, can berealised.

In another embodiment the first locking element is positioned at adistance from an upper side of the upward tongue. This is favourable,since this will commonly result in the situation that the first lockingelement is positioned at a lower level than the upward aligning edge ofthe tile, which has the advantage that the maximum deformation of thesecond coupling part can be reduced, whereas the connection process anddeformation process can be executed in successive steps. Lessdeformation leads to less material stress which is in favour of the lifespan of the coupling part(s) and hence of the tile(s). In thisembodiment the second locking element is complementary positioned at adistance from an upper side of the downward groove.

In an embodiment the mutual angle enclosed by at least a part of a sideof the upward tongue facing toward the upward flank and the upward flank(and/or the normal of the upper side of the base layer) is substantiallyequal to the mutual angle enclosed by at least a part of a side of thedownward tongue facing toward the downward flank and the downward flank(and/or the normal of the lower side of the base layer). A close-fittingconnection of the two tongue parts to each other can hereby be realized,this generally enhancing the firmness of the coupling between the twotiles. In an embodiment variant the angle enclosed by on the one handthe direction in which at least a part of a side of the upward tonguefacing toward the upward flank extends and on the other the upward flankand/or the normal of the upper side of the base layer lies between 0 and60 degrees, in particular between 0 and 45 degrees, more particularlybetween 0 and 10 degrees. In another embodiment variant the angleenclosed by on the one hand the direction in which at least a part of aside of the downward tongue facing toward the downward flank extends andon the other hand the downward flank and/or the normal of the lower sideof the base layer lies between 0 and 60 degrees, in particular between 0and 45 degrees, more particularly between 0 and 10 degrees. The eventualinclination of the tongue side facing toward the flank usually alsodepends on the production means applied to manufacture the tile. In anembodiment inclination of the downward aligned edge is less than theinclination of at least an upper part of the upward flank, as result ofwhich an expansion chamber will be formed between both surface whichwill be favourable to allow play and to compensate expansion, e.g. dueto moist absorption by the tiles.

In a variant at least a part of an upper side of the upward tongueextends in a direction toward the normal of the upper side of the baselayer. This has the result that the thickness of the upward tonguedecreases in the direction of the side of the tongue facing away fromthe upward flank. By having the downward groove substantially connect tothe upper side of the upward tongue, in a coupled position of two tilesaccording to the invention wherein an upper side of the downward grooveextends in the direction of the normal of the lower side of the baselayer, a second coupling part can be provided which is on the one handrelatively strong and solid and can on the other guarantee sufficientresilience to enable a coupling to be realized to a first coupling partof an adjacent tile.

The aligning edges are formed by a flat surface so as to allow guidingof another coupling part during the process of coupling two tiles toproceed be generally in as controlled a manner as possible. Applicationof a rounded aligning edge is, however, also imaginable. In anotherembodiment variant at least a part of the aligning edge of the secondcoupling part has a substantially flatter orientation than at least apart of the upward flank of the first coupling part. By applying thismeasure there is generally created in a coupled position an air gapbetween the aligning edge of the second coupling part and a flank of thefirst coupling part. This clearance intentionally created between thetwo coupling parts is usually advantageous during coupling of adjacenttiles, since this clearance does not prevent a temporary deformation ofthe coupling parts, this facilitating coupling of the coupling parts.Furthermore, the created clearance is advantageous for the purpose ofabsorbing expansion of the tile, for instance resulting fromenvironmental temperature changes.

In an embodiment variant a part of the upward flank of the firstcoupling part connecting to the base layer forms a stop surface for atleast a part of the side of the downward tongue facing away from thedownward flank. In this way a close fitting of at least the upper sideof the tiles can be realized, this usually being advantageous from auser viewpoint. A part of the upward flank of the first coupling partconnecting to the base layer is here preferably oriented substantiallyvertically. At least a part of the side of the downward tongue facingaway from the downward flank is here also preferably orientedsubstantially vertically. Applying substantially vertical stop surfacesin both coupling parts has the advantage that in the coupled positionthe coupling parts can connect to each other in relatively close-fittingand firm manner.

It is generally advantageous for the upward groove to be adapted toreceive with clamping fit a downward tongue of an adjacent tile.Receiving the upward groove, or at least a part thereof, with clampingfit in the downward tongue has the advantage that the downward tongue isenclosed relatively close-fittingly by the upward groove, this usuallyenhancing the firmness of the coupled construction. The same applies forthe embodiment variant in which the downward groove is adapted toreceive with clamping fit an upward tongue of an adjacent tile.

In an embodiment variant the upward flank and the downward flank extendin a substantially parallel direction. This makes it possible to connectthe flanks, as well as the locking elements, relatively closely to eachother in a coupled position, this generally enhancing the locking effectrealized by the locking elements.

In another embodiment variant the first locking element comprises atleast one outward bulge, and the second locking element comprises atleast one recess, which outward bulge is adapted to be at leastpartially received in a recess of an adjacent coupled tile for thepurpose of realizing a locked coupling. This embodiment variant isgenerally advantageous from a production engineering viewpoint. Thefirst locking element and the second locking element preferably take acomplementary form, whereby a form-fitting connection of the lockingelements of adjacent tiles to each other will be realized, thisenhancing the effectiveness of the locking. Alternatively, the secondlocking element comprises at least one outward bulge, and the firstlocking element comprises at least one recess, which outward bulge isadapted to be at least partially received in a recess of an adjacentcoupled tile for the purpose of realizing a locked coupling. It is alsoconceivable that, in an embodiment not forming part of the presentinvention, the first and second locking elements are not formed by abulge-recess combination, but by another combination of co-actingprofiled surfaces and/or high-friction contact surfaces. In this latterembodiment, the first locking element and/or the second locking elementmay be formed by a (flat of otherwise shaped) contact surface composedof a, optionally separate, plastic material configured to generatefriction with the other locking element of another tile in engaged(coupled) condition. Examples of plastics suitable to generate frictioninclude:

-   -   Acetal (POM), being rigid and strong with good creep resistance.        It has a low coefficient of friction, remains stable at high        temperatures, and offers good resistance to hot water;    -   Nylon (PA), which absorbs more moisture than most polymers,        wherein the impact strength and general energy absorbing        qualities actually improve as it absorbs moisture. Nylons also        have a low coefficient of friction, good electrical properties,        and good chemical resistance;    -   Polyphthalamide (PPA). This high performance nylon has through        improved temperature resistance and lower moisture absorption.        It also has good chemical resistance;    -   Polyetheretherketone (PEEK), being a high temperature        thermoplastic with good chemical and flame resistance combined        with high strength. PEEK is a favorite in the aerospace        industry;    -   Polyphenylene sulfide (PPS), offering a balance of properties        including chemical and high-temperature resistance, flame        retardance, flowability, dimensional stability, and good        electrical properties;    -   Polybutylene terephthalate (PBT), which is dimensionally stable        and has high heat and chemical resistance with good electrical        properties;    -   Thermoplastic polyimide (TPI) being inherently flame retardant        with good physical, chemical, and wear-resistance properties.    -   Polycarbonate (PC), having good impact strength, high heat        resistance, and good dimensional stability. PC also has good        electrical properties and is stable in water and mineral or        organic acids; and    -   Polyetherimide (PEI), maintaining strength and rigidity at        elevated temperatures. It also has good long-term heat        resistance, dimensional stability, inherent flame retardance,        and resistance to hydrocarbons, alcohols, and halogenated        solvents.

The performance of many of the above polymers can also be enhanced usingcertain additives which reduce fiction (if desired). The high-frictionpolymer material may, for example, be applied as a (separate) materialstrip. Application of this high-friction polymer material allows thedistant side (outer side) of the upward tongue and the downward flank tohave a substantially flat design.

In an embodiment of the tile according to the invention the firstlocking element is positioned at a distance from an upper side of theupward tongue. Positioning the first locking element at a distance fromthe upper side of the upward tongue has a number of advantages. A firstadvantage is that this positioning of the first locking element canfacilitate the coupling between adjacent tiles, since the first lockingelement will be positioned lower than (a lower part of) the aligningedge of the upward tongue, whereby the coupling between two couplingparts can be performed in stages. During the coupling process the tonguesides facing toward the associated flanks will first engage each other,after which the locking elements engage each other, this generallyrequiring a less great maximum pivoting (amplitude), and therebydeformation of a second coupling part of an adjacent tile, than if thefirst aligning edge and the first locking element were to be located atmore or less the same height. A further advantage of positioning thefirst locking element at a distance from an upper side of the upwardtongue is that the distance to the resilient connection between eachcoupling part and the base layer, generally formed by the resilientbridge of each coupling part, is increased, whereby a torque exerted onthe coupling parts can be compensated relatively quickly by the lockingelements, which can further enhance the reliability of the locking. Incase the first locking element and second locking element would not beapplied, it may be favourable that side of the upward tongue facing awayfrom the upward flank is positioned at a distance from the downwardflank in coupled condition of adjacent tiles.

In a preferred embodiment, a side of the downward tongue facing awayfrom the downward flank is provided with a third locking element, andwherein the upward flank is provided with a fourth locking element, saidthird locking element being adapted to cooperate with a fourth lockingelement of another tile. This would result in an additional innerlocking mechanism, which could further improve the stability andreliability of the coupling. Also in this embodiment, the third (orfourth) locking element may be formed by one or more bulges, wherein thefourth (or third) locking element may be formed by one of morecomplementary recesses adapted to co-act with said bulges in coupledcondition of adjacent tiles. It is imaginable that shortest distancebetween an upper edge of the downward tongue and a lower side of thebase layer defines a plane, wherein the third locking element and atleast a part of the downward tongue are situated at opposite sides ofsaid plane. In this case, the third locking element protrudes withrespect to the tile edge defined by an upper section or upper surface ofthe tile. Here, the third locking element may protrude into an adjacenttile in a coupled condition which may further improve the tile coupling.It is advantageous in case the minimum distance between said lockingsurface and an upper side of the tile is smaller than the minimumdistance between an upper side of the upward tongue and said upper sideof the tile. This will reduce the maximum deformation of the second (orfist) coupling part, whereas the connection process and deformationprocess can be executed in successive steps. Less deformation leads toless material stress which is in favour of the life span of the couplingpart(s) and hence of the tile(s).

Each tile to be used in the system according to the invention comprisesone or more first coupling parts, one or more second coupling parts,and/or a combination of at least one first coupling part and at leastone second coupling part. It is conceivable that one or more (remaining)edges of a tile is/are provided with an alternative coupling part, suchas a conventional angling down profile, as for example disclosed in U.S.Pat. No. 4,426,820, the content of which is incorporated in thisdocument by reference. Such an angling down profile typically comprisesa first edge (third coupling part) comprising a sideward tongueextending in a direction substantially parallel to the upper side of thepanel, the bottom front region of said sideward tongue being rounded atleast partly, the bottom back region of said tongue being configured asbearing region, wherein the bottom back region is located closer to thelevel of the upper side of the panel than a lowest part of the bottomfront region, and an opposite, second edge (fourth coupling part)comprising a recess for accommodating at least a part of the sidewardtongue of a further panel, said recess being defined by an upper lip anda lower lip, said lower lip being provided with a upwardly protrudingshoulder for supporting the bearing region of the sideward tongue, thesideward tongue being designed such that locking takes place by anintroduction movement into the recess of the sideward tongue a furtherpanel and a angling down movement about an axis parallel to the firstedge, as a result of which a top side of the sideward tongue will engagethe upper lip and the bearing region of the sideward tongue will besupported by and/or facing the shoulder of the lower lip, leading tolocking of adjacent panels at the first and second edges in bothhorizontal direction and vertical direction.

In an embodiment a plurality of sides (or edges) of the tile comprise afirst coupling part, and a plurality of sides of the tile comprise asecond coupling part, wherein each first coupling part and each secondcoupling part lie on opposite sides of the tile. In this way each sideof the tile can be provided with a coupling part, this increasing thecoupling options of the tile. By positioning the first coupling part andthe second coupling part on opposite sides it will be relatively simplefor a user to lay a floor formed by tiles according to the invention,since each tile can be formed in the same way. Adjacent edges of a tilemay be provided with different types coupling parts.

The invention also relates to a tile covering, in particular floorcovering, consisting of mutually coupled tiles according to theinvention. The invention also relates to a tile for use in multi-purposetile system according to the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be elucidated on the basis of non-limitativeexemplary embodiments shown in the following figures. Herein shows:

FIG. 1 schematically a transverse side view of a first embodiment of afloor tile according to the invention;

FIG. 2 a a schematic representation of coupling parts of a secondembodiment of a floor tile according to the invention;

FIG. 2 b a schematic representation of a coupled position of two floortiles comprising coupling parts as shown in FIG. 2 a;

FIG. 3 a a schematic representation of coupling parts of a thirdembodiment of a floor tile according to the invention;

FIG. 3 b a schematic representation of a coupled position of two floortiles comprising coupling parts as shown in FIG. 3 a;

FIG. 4 a a schematic representation of coupling parts of a fourthembodiment of a floor tile according to the invention;

FIG. 4 b a schematic representation of a coupled position of two floortiles comprising coupling parts as shown in FIG. 4 a;

FIG. 5 schematically a side view of the laminate details of a possibleembodiment of a floor tile according to the invention;

FIG. 6 a perspective view of the laminate details of a further possibleembodiment of a floor tile according to the invention;

FIG. 7 a schematic top view of a floor tile in a first possiblearrangement;

FIG. 7 b a schematic top view of a floor tile in a second possiblearrangement;

FIG. 7 c a schematic top view of a second embodiment of the floor tilewith the arrangement shown in FIG. 7 b;

FIG. 7 d a schematic top view of first configuration of a tile systemcomprising a plurality of floor tiles as shown in FIGS. 7 a -c;

FIG. 7 e a schematic top view of a second configuration of a tile systemcomprising a plurality of floor tiles as shown in FIGS. 7 a -b;

FIG. 7 f schematic a top view of a third configuration of a tile systemcomprising a plurality of floor tiles as shown in FIGS. 7 a -b;

FIG. 7 g a schematic top view of a fourth configuration of a tile systemcomprising a plurality of floor tiles as shown in FIGS. 7 a -b;

FIG. 7 h a top view of a fifth configuration of a tile system comprisinga plurality of floor tiles as shown in FIGS. 7 a-b ; and

FIG. 8 a schematic representation of a fifth embodiment of a floor tileaccording to the invention.

DESCRIPTION OF THE INVENTION

FIG. 1 shows a side view of a rectangular multi-purpose floor tile 101according to the invention. Floor tile 101 comprises a rigid base layer102 which is at least partially made of a closed cell foam plasticmaterial, provided with a toughening agent, provided with an upper side102 a and a lower side 102 b, and coupling parts 103, 104 positioned onopposite (longitudinal) sides of rigid base layer 102 and connectedintegrally to rigid base layer 102. A first coupling part 103 comprisesan upward tongue 105, an upward flank 106 and an upward groove 109formed between upward tongue 105 and upward flank 106. A side 105 a ofupward tongue 105 facing toward upward flank 106 extends in thedirection of the normal N1 of the upper side 102 a of rigid base layer102. The tangent R1 and the normal N1 of upper side 102 a of rigid baselayer 102 are thus directed toward each other (converging orientation),wherein the angle enclosed by R1 and N1 amounts to 0-10, in particularabout 3-5 degrees. Another side 105 b of upward tongue 105 facing towardupward flank 106 forms an aligning edge enabling facilitated realizationof a coupling to an adjacent floor tile. As shown, this side 105 bfunctioning as aligning edge is directed away from the normal N1 ofupper side 102 a of the rigid base layer. An upper side 105 d of upwardtongue 105 does however extend in the direction of the normal N1 ofupper side 102 a of rigid base layer 102, and runs inclining downward inthe direction of the side 105 e of upward tongue 105 facing away fromupward flank 106. This chamfering provides the option of giving thecomplementary second coupling part 104 a more robust and thereforestronger form. The side 105 e of upward tongue 105 facing away fromupward flank 106 is oriented substantially vertically and is moreoverprovided with a first locking element 107 in the form of an outwardbulge 107. A lower part 106 a of upward flank 106 is orienteddiagonally, while an upper part 106 b of upward flank 106 is shown to besubstantially vertical and forms a stop surface for second coupling part104. A lower wall part 109 a of upward groove 109 is orientedsubstantially horizontally in this exemplary embodiment. A bridge 108lying between lower wall part 109 a of upward groove 109 and a lowerside 103 a has a somewhat elastic nature and is adapted to allow upwardtongue 105 to pivot relative to upward flank 106, this resulting in a(temporary) widening of upward groove 109, whereby coupling of floortile 101 to an adjacent floor tile can be facilitated. Second couplingpart 104 is substantially complementary to first coupling part 103.Second coupling part 104 comprises a downward tongue 110, a downwardflank 111 and a downward groove 112 formed between downward tongue 110and downward flank 111. A side 110 a of downward tongue 110 facingtoward downward flank 111 lies in the direction of the normal N2 of thelower side 102 b of rigid base layer 102. This means that a tangent R2of side 110 a of downward tongue 110 and the normal of the lower side102 b of rigid base layer 102 are mutually converging. In this exemplaryembodiment the tangent R2 and the normal N2 enclose a mutual angle of 5degrees. A side 110 b facing away from downward flank 111 is diagonallyoriented, but has a flatter orientation than the complementary side 106a of upward flank 106, whereby a gap (air space) will be formed in thecoupled position, which will generally facilitate coupling between twofloor tiles 101. The inclining side 110 b of downward tongue 110 alsofunctions as aligning edge for the purpose of further facilitatingcoupling between two floor tiles 101. Another side 110 c facing awayfrom downward flank 111 takes a substantially vertical form and forms acomplementary stop surface for stop surface 106 b of upward flank 106(of an adjacent floor tile). Downward tongue 110 is further providedwith a side 110 d which is facing toward downward flank 111 and whichfunctions as aligning edge for first coupling part 103 of an adjacentfloor tile. Because upper side 105 d of upward tongue 105 has aninclining orientation, an upper side 112 a of downward groove 112likewise has an inclining orientation, whereby the (average) distancebetween upper side 112 a of downward groove 112 and an upper side 104 aof second coupling part 104 is sufficiently large to impart sufficientstrength to second coupling part 104 as such. Downward flank 111 isoriented substantially vertically and is provided with a second lockingelement 113 in the form of a recess 113 adapted to receive the outwardbulge 107 of upward tongue 105 (of an adjacent floor tile).

A bridge 114 lying between upper side 112 a of downward groove 112 andupper side 104 a has a somewhat elastic nature and is adapted to allowdownward tongue 110 to pivot relative to downward flank 111, thisresulting in a (temporary) widening of downward groove 112, wherebycoupling of floor tile 101 to an adjacent floor tile can be facilitated(not shown). The shown floor tile 101 can be part of a multi-purposetile system according to the invention.

FIG. 2 a shows a schematic representation of coupling parts 203, 204 ofa second embodiment of a floor tile 201 according to the invention. FIG.2 b shows a schematic representation of the coupled position of twofloor tiles 201 a, 201 b comprising coupling parts 203, 204 as shown inFIG. 2 a.

The first coupling part 203 and the second coupling part 204 have equalfunctionalities as the first and second coupling parts shown in FIG. 1 .The first coupling part 203 comprises an upward tongue 205, an upwardflank 206 lying at a distance from the upward tongue 205 and an upwardgroove 209 formed between the upward tongue 205 and the upward flank206. The second coupling part 204 comprises a downward tongue 210, adownward flank 211 lying at a distance from the downward tongue 210, anda downward groove 212 formed between the downward tongue 210 and thedownward flank 211. A side 210 b facing away from the downward flank 211is diagonally oriented. The side 210 b has a substantially straightdesign, where the complementary side 206 a of the upward flank 206 has arounded design. An air gap 230 is formed in the coupled position shownin FIG. 2 b .

The first coupling part 203 comprises a first locking element 207 whichis adapted for co-action with a second locking element 213 which isprovided in the flank 211 of the second coupling part 204.

The difference between the embodiment shown in FIGS. 2 a-b and FIG. 1 isthat the tongues 205, 210, flanks 206, 211 and grooves 209, 212 have asubstantially rounded design.

FIG. 3 a shows a schematic representation of coupling parts 303, 304 ofa third embodiment of a floor tile 301 according to the invention. FIG.3 b shows a coupled position of two floor tiles 301 a, 301 b comprisingcoupling parts 303, 304 as shown in FIG. 3 a . The air gap 330 formedbetween a side 310 b of the downward tongue and the complementary side306 a of the upward flank 206 is substantially smaller than the air gapshown in the embodiment of FIG. 2 b.

FIG. 4 a shows a schematic representation of coupling parts 403, 404 ofa fourth embodiment of a floor tile 401 according to the invention. FIG.4 b shows a schematic representation of the coupled position of twofloor tiles 401 a, 401 b comprising coupling parts 403, 404 as shown inFIG. 4 a . The floor tile 401 comprises a rigid base layer 402 which isat least partially made of a closed cell foam plastic material. The tile401 comprises a third locking element 440 and a complementary fourthlocking element 441. A side 410 b of the downward tongue 410 facing awayfrom the downward flank 411 is provided with the third locking element440. The upward flank 406 of the first coupling part 403 is providedwith the fourth locking element 441. The third locking element 440 isadapted to cooperate with the fourth locking element 441 of anothertile, as shown in FIG. 4 b . FIG. 4 a shows the co-action between thethird locking element 440 and the fourth locking element 441 in coupledcondition of two tiles 401 a, 401 b. The co-action defines a tangent T1which encloses an angle A1 with a plane defined by the tile 401, whichangle A1 is smaller than an angle A2 enclosed by said plane defined bythe tile 401 and a tangent T2 defined by a co-action between an inclinedpart of a side of the upward tongue 405 facing toward the upward flank406 and an inclined part of a side 410 a of the downward tongue 410facing toward the downward flank 411. The greatest difference betweenangle A1 and angle A2 is situated between 5 and 10 degrees. The thirdlocking element 440 comprises a locking surface 443 having a distal end442 which is distally located from a plane 450 defined by an upper side406 a of the upward flank 406 and a side 410 d of the downward tongue410 facing away from the downward flank 411, in a coupled condition.

The distance between said locking surface 443 and an upper side 402 a ofthe tile 401 is smaller than the distance between an upper side 405 a ofthe upward tongue 405 and said upper side 402 a of the tile 401. FIG. 4b shows that a side 405 e of the upward tongue 405 facing away from theupward flank 406 is positioned at a distance from the downward flank411. A first air gap 430 a is formed between the upward tongue 405 andthe downward flank 411. A second air gap 430 b is formed between theupward groove 409 and the downward tongue 410. The downward tongue 410is in contact with a support surface 431 of the upward groove 409. Athird air gap 430 c is formed between the side 410 b of the downwardtongue 410 facing away from the downward flank 411 and the upward flank406.

The bottom of the floor tile 401 comprises a bottom recess 432 whichextends from point X to the end side 405 e of the upward tongue 405.Preferably, the starting point X of the bottom recess 432 is at adistance d from a side 405 b of the upward tongue 405 facing towards theupward flank 406.

FIG. 5 show a side view of the laminate details of a possible embodimentof a floor tile 501 according to the invention. The floor tile 501comprises a rigid foam base layer 502 formed of a poly-foam or foamedplastic material having a lower side or bottom foam surface 502 b and anupper side 502 a. The floor tile 501 further comprises an uppersubstrate layer 520, formed of a non-foam plastic or metallic materialand has a lower surface 520 b and an upper surface 520 a. The uppersubstrate layer 520 is provided over the upper foam surface 502 a of therigid base layer 502. An adhesive 521, which can be a layer or coating,is provided between the upper surface 502 a of the rigid base layer 502and the lower surface 520 b of the upper substrate layer 520 to join theupper substrate layer 520 and the rigid base layer 502 together. Thefloor tile 501 can possibly include a design pattern or a decorativeappearance of any selected type on or at the upper surface 520 a of thesubstrate layer 520. The design pattern can be a wood grain design, amineral grain design that resembles marble, granite or any other naturalstone grain, or a colour pattern, colour blend or single colour to namejust a few design possibilities. The decoration or design pattern can beprinted onto or otherwise applied to the upper surface 520 a of theupper substrate layer 520, but is preferably provided on a separateprinting film or design layer 522 of any suitable known plasticmaterial. The design layer 522 is covered by a transparent orsemi-transparent abrasion resistant wear layer 523 of known material andfabrication through which the design layer 522 can be viewed. The top ofthe wear layer 523 is the top surface of the floor tile 501. The floortile 501 can be provided with any of the coupling elements shown in theprevious figures.

The upper substrate layer 520, the design layer 522 and the wear layer523 can be initially laminated together to form an upper substratelaminate subassembly 524. The laminate subassembly 524 and the foam baselayer 502 can then be laminated together to form the tile 501.

FIG. 6 shows a perspective view of the laminate details of a furtherpossible embodiment of a floor tile 601 according to the invention,wherein the layers of the laminate are shown separated partially. Thefloor tile 601 is provided with coupling parts 603 at the edge portionsof the tile 601. This can be any suitable coupling part 603, for examplethe coupling parts shown in FIGS. 1-4 . The floor tile 601 comprises asubstantially rigid base layer 602 which is at least partially made ofclosed cell foam polyvinyl chloride material, for example polyvinylchloride comprising sodium carbonate filler. The floor tile 601 furthercomprises an upper substrate layer 620, or reinforcing layer 620,affixed to the upper side of the base layer 602. In the shownembodiment, the reinforcing layer 620 is at least partially made ofpolyvinyl chloride resin comprising a plasticizer and a carbonatefiller. The reinforcing layer 620 enhances the durability of the floortile 601 and provides resistance against scratches and other smalldamages. A design layer 622 is provided on top of the reinforcing layer620. The design layer 622 is preferably a thermoplastic film layer. Thedesign layer 622 is covered by a transparent or semi-transparentabrasion resistant wear layer 623 through which the design layer 622 canbe viewed. The wear layer 623 is a protection layer and is preferably atleast partially made of a polyvinyl chloride resin comprising a DOTPplasticizer and calcium and zinc stearate. The top surface of the floortile 601 comprises a ceramic bead polymer layer 626. The ceramic beadpolymer layer 626 forms a protective overlay 626 due to its wearresistance and corrosion and erosion resistance. The floor tile 601further comprises a backing layer 625. The backing layer 625 preferablyhas good sound damping properties. The backing layer 625 is preferablyshock-absorbing. The floor tile 601 is fully waterproof and has a verygood moisture stability. The possible embodiment of FIG. 6 may compriseall of the abovementioned layers, or any number of the mentioned layersin combination. For instance, the ceramic bead polymer layer 626 mayoptionally be omitted.

FIGS. 7 a-7 h are merely illustrative and are not directed toembodiments according to the present invention.

FIG. 7 a shows a top view of a schematic representation of a floor tileA in a first possible arrangement. The floor tile A comprises aplurality of first coupling parts G3L provided at a first edge portionA1 of the tile A and at a second edge portion A2. The floor tile Acomprises a plurality of second coupling parts T3L provided at a thirdedge portion A3, opposite of first edge portion Al, and at a fourth edgeportion A4. The first coupling parts G3L can be any type of firstcoupling part G3L comprising a, preferably single, upward tongue, atleast one upward flank lying at a distance from the upward tongue and asingle upward groove formed between the upward tongue and the upwardflank, according to the invention. The second coupling parts T3L can beany type of second coupling part comprising a, preferably single,downward tongue, at least one downward flank lying at a distance fromthe downward tongue, and a single downward groove formed between thedownward tongue and the downward flank, according to the invention. TileA has a substantially rectangular design.

FIG. 7 b shows a top view of a schematic representation of a floor tileB in a second possible arrangement. The floor tile B is a mirror imageof the floor tile A shown in FIG. 7 a . The floor tile B comprises aplurality of first coupling parts G3L provided at a third edge portionB3 of the tile B and at a second edge portion B2. The floor tile Bcomprises a plurality of second coupling parts T3L provided at a firstedge portion B1 and at a fourth edge portion B4. Tile B has asubstantially rectangular design.

FIG. 7 c shows a top view of a second embodiment of a floor tile C,which has a similar arrangement as the floor tile B shown in FIG. 7 b .However the size of tile C differs from the size of tile B. Tile C has asubstantially square design.

Due to the specific arrangement of first coupling parts G3L and secondcoupling parts T3L, it is possible to create a wide range of possibleconfigurations of tile systems according to the invention. FIGS. 7 d-hshow examples of possible embodiments of configurations of floor tilesystems consisting of mutually coupled tiles A and B and/or C. The tilesA, B, C are configured to co-act in such manner that coupled tiles aresubstantially locked both in a direction parallel to the plane definedby the tiles as well as in a direction perpendicular to said placedefined by the tiles. Tiles with corresponding reference numbers areidentical.

FIG. 7 d shows a top view of a schematic representation of a firstconfiguration of a tile system 700 d, comprising a plurality of floortiles A, B, C as shown in FIGS. 7 a -c. Each substantially square tile Cis coupled with multiple substantially rectangular tiles A, B.

The tiles can possibly include a design pattern or a decorativeappearance at the upper surface of the tile. The design of the tiles canfor example be chosen such that the rectangular tiles A, B have adifferent design than the square tiles C. The tile system 700 d showsthat the rectangular tiles A, B may for instance form a grout framearound the square tiles C.

FIG. 7 e shows a top view of a schematic representation of a secondconfiguration of a tile system 700 e, comprising a plurality of floortiles A, B as shown in FIGS. 7 a-b . The first edge portions A1 and thethird edge portions A3 of each vertical oriented floor tile A areconnected with a plurality of horizontal oriented floor tiles B.

FIG. 7 f shows a top view of a schematic representation of a thirdconfiguration of a tile system 700 f, comprising a plurality of floortiles A, B as shown in FIGS. 7 a-b . The figure shows a herringbonestructure.

FIG. 7 g shows a top view of a schematic representation of a fourthconfiguration of a tile system 700 g comprising a plurality of floortiles A, B as shown in FIGS. 7 a-b . A plurality of series of six A-typefloor tiles is connected to a plurality of series of six perpendicularoriented B-type floor tiles, thereby forming a chessboard pattern.

FIG. 7 h shows a top view of a schematic representation of a fifthpossible configuration of a tile system 700 h comprising a plurality offloor tiles A, B as shown in FIGS. 7 a -b.

FIG. 8 shows a schematic representation of a floor tile 801 comprising aplurality of grooves 860 a, 860 b. The floor tile 801 comprises asubstantially rigid base layer 802 and an upper substrate layer 820. Thegrooves 860 a, 860 b are V-shaped grooves which are located in the baselayer 802. The grooves facilitate bending and/or folding of the tile 801at inside and outside corners of intersecting support surfaces of a tile(not shown). The grooves 860 a, 860 b can be positioned at any preferredlocation of the tile 801. The shape of the grooves 860 a, 860 b can beof any preferred design, however the depth of the grooves 860 a, 860 bshould not extend past the upper surface of the rigid base layer 802. Inthe shown embodiment the floor tile 801 comprises a first coupling part803 and a second coupling part 804, which are equal to the couplingparts shown in FIG. 1 .

Although the figures disclose various embodiments according to theinvention, the features of the embodiments may be combined whereappropriate, all falling within the intended scope of the invention. Onecould for instance imaging the use of various coupling parts in the tilesystems or interchange the coupling parts between the differentembodiments. One could also image to omit the application of asubstantially rigid base layer at least partially made of a closed cellfoam plastic material; instead, another type of, preferably rigid, baselayer could be used in each tile, which alternative base layer may bemade, for example, of at least one material selected from the groupconsisting of: MDF, HDF, synthetic material, such as a thermoplasticlike polyvinyl chloride (PVC), a composite material, in particular adust-(thermo)plastic-composite, a non-foamed plastic material, a mineralmaterial and/or a thermoplastic material which is enriched with one ormore additives. Here, the expression “dust” is understood is smalldust-like particles (powder), like wood dust, cork dust, or non-wooddust, like mineral dust, stone powder, in particular cement. Bycombining bamboo dust, wood dust, or cork dust, or combination thereof,with for example high density polyethylene (HDPE), or polyvinylchloride(virgin, recycled, or a mixture thereof), a rigid and inert core isprovided that does not absorb moisture and does not expand or contract,resulting in peaks and gaps. Although tile commonly has a laminatedstructure (multi-layer structure), the tile according to the inventionmay also be formed by a single layer tile.

Hence, the above-described inventive concepts are illustrated by severalillustrative embodiments. It is conceivable that individual inventiveconcepts may be applied without, in so doing, also applying otherdetails of the described example. It is not necessary to elaborate onexamples of all conceivable combinations of the above-describedinventive concepts, as a person skilled in the art will understandnumerous inventive concepts can be (re)combined in order to arrive at aspecific application.

It will be apparent that the invention is not limited to the workingexamples shown and described herein, but that numerous variants arepossible within the scope of the attached claims that will be obvious toa person skilled in the art.

The verb “comprise” and conjugations thereof used in this patentpublication are understood to mean not only “comprise”, but are alsounderstood to mean the phrases “contain”, “substantially consist of”,“formed by” and conjugations thereof.

The invention claimed is:
 1. A multi-purpose tile system, comprising aplurality of multi-purpose tiles, the tile system comprising firstcoupling parts and at least one second coupling parts, and each tilecomprising: a base layer, wherein the base layer is provided with one ormore folding grooves allowing folding of the tile, an upper substrateaffixed to an upper side of the base layer, wherein said substratecomprises a decorative layer, the at least one first coupling partand/or the at least one second coupling part provided at different edgesof the tile, which the first coupling part comprises an upward tongue,at least one upward flank lying at a distance from the upward tongue anda single upward groove formed between the upward tongue and the upwardflank, wherein: at least a part of a side of the upward tongue facingtoward the upward flank is inclined toward the upward flank, at least aninclined flat or rounded surface of the upward tongue facing toward theupward flank forms a first upward aligning edge for the purpose ofcoupling the at least one first coupling part to the at least one secondcoupling part of an adjacent tile, at least a part of a side of theupward tongue facing away from the upward flank is provided with a firstlocking element which is adapted for co-action with a second lockingelement of the at least one second coupling part of an adjacent tile,which the at least one second coupling part comprises a downward tongue,at least one downward flank lying at a distance from the downwardtongue, and a single downward groove formed between the downward tongueand the downward flank, wherein: at least a part of a side of thedownward tongue facing toward the downward flank is inclined toward thedownward flank, at least an inclined flat or rounded surface of thedownward tongue facing away from the downward flank forms a downwardaligning edge for the purpose of coupling the at least one secondcoupling part to the first coupling part of an adjacent tile, thedownward flank is provided with a second locking element which isconnected substantially rigidly to the downward flank and adapted forco-action with a first locking element of the first coupling part of anadjacent tile, said first and second locking elements being formed by avertical flat portion and a bulge-recess combination, wherein the firstlocking element is positioned at a distance from an upper side of theupward tongue, wherein the second locking element is positioned at adistance from an upper side of the downward groove, and wherein theupward groove is adapted to receive at least a part of the downwardtongue of an adjacent tile, and wherein the downward groove is adaptedto receive at least a part of the upward tongue of an adjacent tile. 2.The tile system as claimed in claim 1, wherein said one or more foldinggrooves are applied in a lower side of said base layer.
 3. The tilesystem as claimed in claim 1, wherein the upper substrate is free offolding grooves.
 4. The tile system as claimed in claim 1, wherein eachof said folding grooves connects both to the lower side and the upperside of the base layer.
 5. The tile system as claimed in claim 1,wherein the upper substrate is flexible.
 6. The tile system as claimedin claim 1, wherein each of said one or more folding grooves isV-shaped.
 7. The tile system as claimed in claim 1, wherein each of saidone or more folding grooves defines an equilateral triangle.
 8. The tilesystem as claimed in claim 1, wherein each of said one or more foldinggrooves is defined by two facing flat folding groove surfaces of thebase layer.
 9. The tile system as claimed in claim 8, wherein eachfolding groove surface and a plane defined by a connecting portion ofthe base layer mutually enclose an angle of 40 degrees.
 10. The tilesystem as claimed in claim 1, wherein the first locking elementcomprises a bulge and the vertical flat portion positioned above thebulge and the second locking element comprises a recess.
 11. The tilesystem as claimed in claim 10, wherein the vertical flat portion, thebulge, and the recess are configured to be in contact with one anotherwhen the tile and the adjacent tile are in a locked position such thatno gap exists between the vertical flat portion, the bulge, and therecess.
 12. The tile system as claimed in claim 1, wherein the baselayer is substantially rigid and at least partially made of a compositecomprising a closed cell foam plastic material and at least one filler,wherein the plastic material of the closed cell foam plastic material ofthe base layer is free of plasticizer, wherein at least one filler isselected from the group consisting of: tale, chalk, wood, calciumcarbonate, titanium dioxide, calcined day, porcelain, a mineral filler,and a natural filler.
 13. The tile system as claimed in claim 12,wherein the weight content of filler in the foamed composite of the baselayer is between 40 and 48%.
 14. The tile system according to claim 12,wherein the base layer is provided with a toughening agent, wherein thebase layer contains 3% to 9% by weight of said toughening agent.
 15. Thetile system as claimed in claim 1, wherein the substantially rigid baselayer is at least partially made of a thermoplastic material.
 16. Thetile system as claimed in claim 1, wherein the base layer has a densityin the range of about 0.1 to 1.5 g/cm³.
 17. The tile system as claimedin claim 1, wherein the upper substrate is at least partially made of atleast one material selected from the group consisting of: metals,alloys, macromolecular materials such as vinyl monomer copolymers and/orhomopolymers; condensation polymers such as polyesters, polyamides,polyimides, epoxy resins, phenol-formaldehyde resins, urea formaldehyderesins; natural macromolecular materials or modified derivatives thereofsuch as plant fibres, animal fibres, mineral fibres, ceramic fibres andcarbon fibres.
 18. The tile system as claimed in claim 1, wherein theupper substrate comprises the decorative layer and an abrasion resistantwear layer covering said decorative layer, wherein a top surface of saidwear layer is the top surface of said tile, and wherein the wear layeris a transparent material, such that the decorative layer is visiblethrough the transparent wear layer.
 19. The tile system as claimed inclaim 1, wherein the decorative layer is digitally printed onto a corelayer.
 20. The tile system as claimed in claim 1, wherein at least onereinforcing layer is situated in between the base layer and the uppersubstrate.
 21. The tile system as claimed in claim 1, wherein the baselayer is composed of a plurality of separate base layer segments affixedto said upper substrate, wherein adjacent base layer segments mutuallyenclose a folding groove.
 22. The tile system as claimed in claim 1,wherein at least a part of the first coupling part and/or at least apart of the second coupling part of each tile is integrally connected tothe base layer.
 23. The tile system as claimed in claim 1, wherein thefirst coupling part and/or the second coupling part allows deformationduring coupling and uncoupling.
 24. The tile system as claimed in claim1, wherein the second coupling part comprises an upper bridge connectingthe downward tongue to the base layer, wherein the upper bridge isconfigured to deform during coupling of adjacent panels, to widen thedownward groove, and wherein a lower side of the upper bridge of thesecond coupling part is at least partially inclined.
 25. The tile systemaccording to claim 1, wherein the upper side of the upward tongue is atleast partially inclined, wherein the inclination of the upper side ofthe upward tongue and the inclination of the bridge part of the secondcoupling part are substantially similar, wherein both inclinations forinstance mutually enclose an angle between 0 and 5 degrees.
 26. The tilesystem as claimed in claim 1, wherein the first locking elementcomprises at least one outward bulge, and that the second lockingelement comprises at least one recess, which outward bulge is adapted tobe at least partially received in a recess of an adjacent coupled tilefor the purpose of realizing a locked coupling.
 27. The tile system asclaimed in claim 1, wherein a side of the downward tongue facing awayfrom the downward flank is provided with a third locking element, andwherein the upward flank is provided with a fourth locking element, saidthird locking element being adapted to cooperate with the fourth lockingelement of another tile.
 28. The tile system as claimed in claim 1,wherein the first coupling part and the second coupling part areconfigured to co-act in such a manner that coupled tiles aresubstantially locked both in a direction parallel to the plane definedby the tiles as well as in a direction perpendicular to said planedefined by the tiles.